manual de mantenimiento de motor mitsubishi s4s de mini cargador cat

7/25/2019 Manual de Mantenimiento de Motor Mitsubishi S4S de Mini Cargador CAT

1/12

1. Maintenance Standards Table ...................................................... 2 1

2. Tightening Torques .......................................................................... 2 6

2.1 Important Bolts and Nuts ................................................................ 2 6

2.2 Standard Bolts ................................................................................ 2 7

2.3 Standard Studs ............................................................................... 2 7

2.4 Standard Plugs ............................................................................... 2 7

3. Sealants and Lubricants Table ..................................................... 2 8

4. Maintenance Schedule ................................................................... 2 9

MAINTENANCE STANDARDS


2/12


3/12

2-1


1. Maintenance Standards Table

Unit: mm (in.)

Nominal Assembly StandardRepair Service

Group Inspection Point Limit Limit Remark Value (Standard Clearance)

(Clearance) (Clearance)

Maximum min1, (no-load) 246020

Adjust governor setting.Minimum min1, (no-load) 75020

Compression pressure 3.2 (33) [469] 2.8 Oil and water temp.MPa (kgf/cm2) [psi] at 300 min1 (29) [413] 20 to 30C (68 to 86F)

0.3 to 0.5 (3 to 5) [43 to 71] 0.15 (1.5)

Engine oil pressure at 1500 min1 [21.3] Oil temperature

MPa (kgf/cm2) [psi] 0.1 (1) [14.2] or more 0.05 (0.5) 70 to 90C (158 to 194F)

at idling [7]

Inlet openBTDC 30

Valve Inlet closeABDC 50

timing Exhaust openBBDC 74

Exhaust closeATDC 30

3 (crank angle)

Valve clearance (cold) 0.25 (0.0098) Both inlet and exhaustvalves

Fuel injection timing BTDC 5

Push belt in ward with

V-belt deflection 10 to 12 (0.4 to 0.5)thumb pressure{98 N (10 kgf) [22 lbf]}and measure deflection.

CrankcaseWarpage of gasket 0.05 (0.0020) 0.20 Regrind if warpage iscontact surface or less (0.0079) minor.

Inside diameter94 94.000 to 94.035 94.200 94.700

Refinish cylinder to(3.70) (3.7008 to 3.7022) (3.7087) (3.7283)

0.25 (0.0098) or 0.50

Cylinder Circularity0.01 (0.0004) (0.0197) oversize of normal

or less value by honing and use the

Cylindricity0.015 (0.0006) same oversize pistons and

or lesspiston rings.

If repair limit is reached,0.09 replace bearings. If is

(0.035) exceeded, regrind journalsClearance between (0.050 to 0.110) (0.200) as journal and use undersize bearings.bearing and journal ([0.0020 to 0.0043]) ([0.0079]) diameter Bearing undersizes:

Main which is 0.25 (0.0098)bearing 78 (3.07) 0.50 (0.0197)

0.75 (0.0295)

Width of thrust journals0.100 to 0.264 0.300

(Clearance between(0.0039 to 0.0104) (0.0118)

Replace thrust plate.thrust and journal)

Inside diameter 14.000 to 14.018 14.100Tappet (0.5512 to 0.5519) (0.5551)

bore Clearance between (0.016 to 0.052) (0.080) If it exceeds the repair limit,tappet and bore ([0.0006 to 0.0021]) ([0.0031]) replace tappets.

If it exceeds the repair limit,Camshaft

Clearance between(0.070 to 0.110) (0.15) refinish bores and install

borecamshaft journal

([0.0028 to 0.0043]) ([0.0059]) bushings, or replaceand bore

camshaft.

General

Crankcase


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2-2


Unit: mm (in.)




Warpage of gasket 0.05 (0.0020) 0.20 Regrind if warpage is

Cylinder contact surface or less (0.0079) minor.

head Compressed thickness 1.2 0.05

of gasket (0.05) (0.002)

DiameterInlet

8

7.940 to 7.955 7.900

of valvevalve

(0.31)

(0.3126 to 0.3132) (0.3110)

stem Exhaust 7.920 to 7.940 7.850valve (0.3118 to 0.3126) (0.3091)

Valve and Clearance Inlet (0.065 to 0.095) (0.150)valve guide between valve ([0.0026 to 0.0037]) ([0.0059])

guide and Exhaust (0.080 to 0.115) (0.200)stem valve ([0.0032 to 0.0045]) ([0.0079])

Height to top of 14 13.9 to 14.1valve guide (0.55) (0.5472 to 0.5551)

Angle 30

ValveInlet 0.4

0.1 (0.004)1.0

sinkage

valve (0.016)

(0.039)Exhaust 0.5Valve valve (0.020)seat

Width1.4

0.14 (0.0055)1.8

(0.055) (0.071)

Up to 1.83Valve margin 2.13 (0.0839) (0.0720) by

refacing

Free length 48.85 (1.92) 47.60 (1.87)

Squareness 1.5 or lessSquareness of ends with

Valverespect to center line

spring Set length 43 (1.69)

Set force176 to 196 147

N (kgf) [lbf](1.8 to 20) (15)[40 to 44] [33]

Inside diameter of 19.010 to 19.030rocker bushing 19 (0.7484 to 0.7492)

Diameter of rocker (0.75) 18.980 to 19.000shaft (0.7472 to 0.7480)

Clearance between (0.010 to 0.050) (0.070)bushing and shaft ([0.0004 to 0.0020]) ([0.0028])

Deflection0.3 (0.012) 1/2 of dial indicator

or less reading

Deflection

0.02 (0.0008) 0.05

or less (0.0020)

Journal diameter78 77.955 to 77.970 77.850 77.100

(3.07) (3.0691 to 3.0697) (3.0650) (3.0354)

Crankpin diameter58 57.955 to 57.970 57.800

(2.28) (2.2817 to 2.2823) (2.2756)

Center to center60

0.04 (0.0016)distance between(2.36)

journal and crankpin

Parallelism betweenRunout : 0.01 (0.004)

journal and crankpinor less (over crankpin

length)

Seatwidth

Valveseat angle Valve

sinkage

Valvemargin

Rocker

arm

Valve

pushrod

Cylinderhead

Crankshaft

Mainmovingparts


5/12

Unit: mm (in.)




Circularity of journal

0.01 (0.0004) 0.03and crankpin

or less (0.0012)Taper of journal and

crankpinFillet radius of journal 3

0.2 (0.008)and crankpin (0.12)

If thrust plate clearanceexceeds the repair limit,replace thrust plates.

End play 3.1 (0.100 to 0.264) (0.300) If it is exceeded, use(Width of shaft thrust (1.22) ([0.0039 to 0.0104]) ([0.0118]) oversize thrust plates.

journal) Thrust plate oversizes:0.15 (0.0059)0.30 (0.0118)

Standard93.955 to 93.985 93.770

(3.6990 to 3.7002) (3.6917)

0.25 (0.0098) 94 94.205 to 94.235 94.020oversize (3.70) (3.7089 to 3.7100) (3.7016)

0.50 (0.0197) 94.455 to 94.485 94.270oversize (3.7187 to 3.7199) (3.7114)

Protrusion0.05 to 0.45

Check bearing clearance.(0.0020 to 0.0177)

No.1 ring(0.07 to 0.11) (0.200)

([0.0028 to 0.0043]) ([0.0079])

No.2 ring(0.045 to 0.085) (0.150)

([0.0018 to 0.0034]) ([0.0059])

Oil ring(0.020 to 0.060) (0.150)

([0.0010 to 0.0026]) ([0.0059])

No.1 ring 0.30 to 0.50

1.50Oil ring (0.0118 to 0.0197)

(0.0591)No.2 ring

0.50 to 0.70(0.0196 to 0.0275)

Diameter30 29.994 to 30.000

(1.18) (1.1809 to 1.1811)

Clearance between 0.000 to 0.016 0.050pin and piston (0.000 to 0.006) (0.0019)

Clearance between (0.020 to 0.051) (0.080)pin and bushing ([0.0008 to 0.0020]) ([0.0032])

Inside diameter of 30 30.020 to 30.045bushing (1.18) (1.1819 to 1.1829)

Bend and twist0.05/100

(0.0019/3.94)or less

Clearance between If service limit is exceeded,crankpin and (0.030 to 0.090) (0.200) replace bearing or regrindconnecting rod ([0.0012 to 0.0035]) ([0.0079]) pin and use undersizebearing bearing.

End play33 (0.15 to 0.35) (0.50)

Replace connecting rod.(1.30) ([0.0059 to 0.0138]) ([0.020])

Flatness 0.15 (0.0059) 0.50

Face runout or less (0.020)

2-3


Mainmovingparts

Outsided

iameter

(atsk

irt)

Crankshaft

Piston

Piston

ring

Piston

pin

Clearancebetween

grooveandring

Clearance

betweenends

Connectingrod

Flywheel


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2-4


Unit: mm (in.)




Deflection0.02 (0.0008) 0.05 Straighten by cold working

or less (0.0020) or replace.

Inlet A= 46.916 6.684 6.184

valve [1.8471 ] (0.2632) (0.2435)Exhaust A= 46.880 6.720 6.220valve [1.8457 ] (0.2646) (0.2450)

No.1, 254 53.94 to 53.96 53.90

(2.13) (2.1236 to 2.1244) (2.1220)

No.353 52.94 to 52.96 52.90

(2.09) (2.0842 to 2.0850) (2.0827)

End play5 (0.10 to 0.25) (0.30)

Replace thrust plates.(0.20) ([0.0039 to 0.0098]) ([0.0118])

Clearance between (0.009 to 0.050) 0.100Replace bushing.

shaft and bushing ([0.0004 to 0.0020]) (0.0040)

End play4.5 (0.05 to 0.20) (0.35)

Replace thrust plates.(1.17) ([0.0020 to 0.0079]) ([0.0138])

Fit (interference) of 3.5 (0.021T to 0.076T)bushing in crankcase bore (1.17) ([0.0008T to 0.0030T])

Backlash0.05 to 0.15 0.25

Replace gears.(0.0012 to 0.0071) (0.0098)

Make shim adjustment.11.77 11.77 to 12.75 Pressure varies by 1 (10)

Valve opening pressure (120) (120 to 130) [142] per 0.1 mmMPa (kgf/cm2) [psi] [1706] [1707 to 1849] (0.004 in.) thickness

of shim.

Test by means of handtester, using diesel fuel,at 20C (68F). If discharge

Spray cone0 pattern is bad even after

angle nozzle is washed in cleandiesel fuel, replacenozzle tip.

Seat shall hold a test pressureOil tightness of needle 2 MPa (20 kgf/cm2) [284 psi] lower

Wash or replace nozzle tip.valve seat than valve opening pressure for

10 seconds.

Diameter of commutator32 31.8 to 32.2 31.4

(1.26) (1.25 to 1.27) (1.24)

Length18 11

(0.71) (0.43)

Brush Spring force, 31 26 to 36 15

N (kgf) [lbf] (3.2) (2.7 to 3.7) (1.5)

[7.0] [5.8 to 8.1] [3.4]0.5 to 2.0

Pinion clearance (0.020 to0.079)

+ 0.1 0.3

+ 0.1 0.3

CamliftC

Journal

diameterC

amshaft

D2

D1

Timinggear

+ 0.004

0.012

+ 0.004 0.012

Idlergear

Fu

elsystem

Injec

tionnozzle

No-load characteristics

Voltage, V Current, A Speed, min1

11 130 or less 3800 or more

Electricalsystem

Starter(12V2.2kW)


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2-5


Unit: mm (in.)




Brush height18.5 5

(0.73) (0.20)

Resistance in slip rings 2.7 to 3.2 ohm at 20C (68F)

Clearance between (0.20 to 0.30) 0.50 Replace oilouter rotor and case ([0.0012 to 0.0018]) [0.0197] pump assembly.

Diameter of main 16 15.985 to 16.000shaft (case side) (0.63) (0.6293 to 0.6299)

Diameter of main shaft 14 13.957 to 13.975(oil pump bushing side) (0.55) (0.5495 to 0.5502)

Clearance between main (0.032 to 0.074) (0.15)Replace pump assembly.

shaft and case ([0.0013 to 0.0029]) ([0.0059])

Clearance between main (0.025 to 0.111) (0.200)Replace pump assembly.

shaft and oil pump bushing ([0.0010 to 0.0044]) ([0.0079])

Clearance between outer (0.13 to 0.15) (0.20)Replace shaft assembly.

and inner rotors ([0.0051 to 0.0059]) ([0.0079])

Clearance between rotors (0.04 to 0.09) (0.15)Replace shaft assembly.

and cover ([0.0016 to 0.0035]) ([0.0059])

Valve opening 0.350.05pressure, (3.50.5)

Relief valveMPa (kgf/cm2) [psi] [507]

Inner rotor bore16 (15.95 to 15.968)

Mainshaft shrinkage fit(0.63) ([0.6279 to 0.6286])

Temp. at which valve 76.52Cstarts opening (1703.6F)

Temp. at which valve90C (194F)

lift is more than 8 (0.3)

Alternator

(12V50A)

Electrical

system

L

ubricationsystem

Oilpump

Cooling

system

Thermostat


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2-6


2. Tightening Torques

2.1 Important Bolts and Nuts

Thread Width Tightening TorqueDescription Dia. Pitch across flats

(M-thread) mm (in.) Nm kgfm lbfft

Cylinder head bolt M12 1.75 19 113 to 123 11.5 to 12.5 83 to 90

Cylinder head plug M16 1.5 14 39.2 to 49.0 4.0 to 5.0 28.9 to 36.2

Rocker cover M8 1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Rocker shaft brackets (long) M8 1.25 12 10.0 to 20.0 1.0 to 2.0 7.23 to 14.5

Main bearing caps M14 2 22 98 to 108 10.0 to 11.0 72 to 80

Connecting rod caps nut M10 1.0 14 49.0 to 59.0 5.0 to 6.0 36.2 to 43.4

Flywheel M12 1.25 17 78.5 to 88.3 8.0 to 9.0 57.9 to 65.1

Camshaft thrust plate M8 l.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40

Front plate M8

1.25 12 10.0 to 13.0 1.0 to 1.3 7.23 to 9.40Timing gear case cover M8 1.25 12 17.0 to 20.0 1.7 to 2.0 12.3 to 14.5

Crankshaft pulley M30 1.5 46 480 to 500 49 to 51 354 to 369

Idler gear thrust plate M10 1.25 14 29.0 to 39.0 3.0 to 4.0 21.7 to 28.9

Oil pan M8 1.25 12 10.0 to 13.0 1.0 to 1.3 7.25 to 9.40

Rear plate M10 1.25 14 54.0 to 65.7 5.5 to 6.7 39.8 to 48.5

Fuel injection pump deliveryM14 1.5 14 44.0 to 54.0 4.5 to 5.5 32.5 to 39.8

valve holders

Fuel injection pump gear nut M12 1.75 19 58.8 to 68.6 6.0 to 7.0 43.4 to 50.6

Fuel injection pump gear(inline, swirl chamber type) M12 1.75 19 58.8 to 68.6 6.0 to 7.0 43.4 to 50.6

(inline, direct injection type) M14 1.5 22 83.4 to 98.0 8.5 to 10.0 61.5 to 72.3

Fuel return pipe nuts M10 1.25 17 20.6 to 24.5 2.1 to 2.5 15.2 to 18.1

Fuel return pipe flare nut M10 1.25 14 17.7 to 21.6 1.8 to 0.22 13.0 to 15.9

Fuel injection pump overflow valve M12 1.0 17 20.0 to 29.0 2.0 to 3.0 14.5 to 21.7

Fuel injection pipe nuts M12 1.5 17 26.5 to 32.4 2.7 to 3.3 19.5 to 23.9

Oil pump gear M10 1.25 14 28.0 to 38.0 2.9 to 3.9 21.0 to 28.2

Oil pan drain plug M14 1.5 17 34.0 to 44.0 3.5 to 4.5 25.3 to 32.5

Oil pressure relief valve M22

1.5 27 44.1 to 53.9 4.5 to 5.5 32.5 to 39.8Coolant drain plug l/418NPTF 14 35.3 to 43.1 3.6 to 4.4 26.0 to 31.8

Thermostat M16 1.5 19 20.6 to 24.5 2.1 to 2.5 15.2 to 18.1

Exhaust manifold (bolt only) (with spacer) M8 1.25 12 27.5 to 33.3 2.8 to 3.4 20.3 to 24.6

Starter terminal B M8 1.25 12 9.81 to 11.8 1.0 to 1.2 7.23 to 8.68

Alternator pulley M16 1.5 24 98 to 137 10.0 to 14.0 72.3 to 101.3


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2-7


2.2 Standard Bolts

2.3 Standard Studs

2.4 Standard Plugs

Remarks: 1. The torque values shown above are for the bolts with spring washers.

2. Do not apply any oil to the bolt threads.

Thread Width Tightening TorqueDescription Dia. Pitch across flats

(M-thread) mm (in.) Nm kgfm lbfft

Glow plug (body) M10 1.25 12 15.0 to 20.0 1.5 to 2.0 10.8 to 14.5

Glow plug (terminal) M4 0.7 7 1.0 to 1.5 0.10 to 0.15 0.72 to 1.08

Nozzles tip retaining nut (to engine) M20 1.5 21 53.0 to 64.7 5.4 to 6.6 39.1 to 47.7

Thermostat case M8 1.25 12 17.0 to 20.0 1.7 to 2.0 12.3 to 14.5

Thread DiameterTorque

(mm)4T 7T

Nm kgfm lbfft Nm kgfm lbfft

M6 2.94 to 4.90 0.3 to 0.5 2.17 to 3.62 7.85 to 9.80 0.8 to 1.0 5.79 to 7.23

M8 9.80 to 12.7 1.0 to 1.3 7.23 to 9.40 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

M10 17.7 to 24.5 1.8 to 2.5 13.0 to 18.1 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4

M12 29.4 to 41.2 3.0 to 4.2 21.7 to 30.4 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2

Thread Diameter

Torque (tap end)

(mm)For driving in aluminum materials For driving in ferrous materials


M8 4.90 to 5.90 0.50 to 0.60 3.62 to 4.34 11.8 to 13.7 1.2 to 1.4 8.68 to 10.1

M10 12.7 to 14.7 1.3 to 1.5 9.40 to 10.8 21.6 to 25.5 2.2 to 2.6 15.9 to 18.8

Torque

Thread Diameter For aluminum materials For ferrous materials


NPTF 1/16 4.90 to 7.85 0.5 to 0.8 3.62 to 5.79 7.85 to 11.8 0.8 to 1.2 5.79 to 8.68

PT 1/8 7.85 to 11.8 0.8 to 1.2 5.79 to 8.68 14.7 to 21.6 1.5 to 2.2 10.8 to 15.9

PT 1/4, NPTF 1/4 19.6 to 29.4 2.0 to 3.0 14.5 to 21.7 34.3 to 44.1 3.5 to 4.5 25.3 to 32.5PT 3/8 53.9 to 73.5 5.5 to 7.5 39.8 to 54.2


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2-8


3. Sealants and Lubricants Table

Apply to Mating Parts Sealant or Lubricant How to Use

Oil pan Crankcase ThreeBond 1207C Apply to seal.

Rear bearing cap seat on crankcase Rear bearing cap ThreeBond 1212Apply to corners before

installing cap.

Side seals Crankcase rear ThreeBond 1212 Apply to side seals.bearing cap

Cylinder head coolant hole plug Cylinder head ThreeBond 1386D Apply to plug hole.

Crankcase coolant hole plug Crankcase ThreeBond 1386D Apply to plug hole.

Crankcase oil hole plug Crankcase ThreeBond 1386D Apply to plug hole.

Return oil hole plug hole Crankcase ThreeBond 1386D Apply to plug hole.

Crankshaft threadsCrankshaft pulley

ThreeBond 1212Apply to crankshaft thread

nut before tightening nut.

Rear gasketCrankcase and rear

ThreeBond 1212Apply to both sides of rear

plate gasket.

CAUTION

When changing parts, be sure to use OEM

designed parts. Unless OEM designed parts

are used, the exhaust emission warranty will

be voided.

Modification to the fuel system can only bedone under these circumstances:

Fuel and exhaust system repairs must only

be conducted by an authorized CAT lift truck

dealer.

Tampering or adjusting the fuel system

components outside the manufacturers

specs will void the warranty.

The fuel injection pump must be replaced as

an assembly.


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2-9


4. Maintenance Schedule

(1) Use the service meter to determine servicing

intervals.

(2) The servicing intervals in the schedule are for an

average operating conditions. Service the engine

earlier than the scheduled intervals if necessary.(The intervals depends on application, operating

conditions and fuel oil and lube oil used in the

engine. Adjust the intervals to meet the actual

operating conditions.)

(3) Perform service on items at multiples of the

original requirement. For example, at Every 200

service hours, also service those items listed under

Every 50 service hours and Every 10 service hours.

Check, clean, wash or adjust.

Change.

S Rely on Cat lift truck dealer if necessary.

1 Cooling fan Check

2 Engine coolant Check level

3 Battery electrolyte Check level Add distilled water as required. (Note 1)

4 Engine (exhaust, noise, vibration) Check

5 Engine oil Check level

6 Fuel Check level

7 Fuel hose, pipes, joints Check

8 V-Belt (fan and alternator) Check tension

9 Air cleaner element Clean (Note 2)

No. ItemInterval

RemarksEvery day

(10 hrs)

Weekly

(10 hrs)

Action

Notes: 1. Not required if battery type is full maintenance free.

2. In corrosive or abrasive environments, clean, lubricate, or change more frequently.

3. When fuel with poor quality is used, check, drain, and change more frequently.

Daily/Weekly Inspection


12/12

2-10


Lubrication Engine oil Change Ssystem

Oil filter Change S

Engine Cylinder head bolt, manifold nut Checkbody (bolts & nuts of engine exterior)

Fuel system Engine idle speed Check

Injection nozzle Check S

Fuel filter Change S (Note 3)Fuel hose Change Replace in 2-4 years

Cooling Radiator fin Check/Cleansystem

Engine coolant Change

Radiator cap, rubber hose Check

Intake & ex- Intake & exhaust valve clearance Checkhaust system

Air cleaner element Change

Electrical Battery electrolyte specific gravity Check (Note 1)system

Alternator Check S

Starter Check S

1stmonthor200hrsonly

afterdelivery

ofnewtruck

Every3monthsor

500servicehours

Every6monthsor

1000servicehours

Yearlyor

every2000servicehours

Group Item

Interval

Remarks

Maintenance Schedule

Action

Check, clean, wash or adjust.

Change.

S Rely on Cat lift truck dealer if necessary.

Notes: 1. Not required if battery type is full maintenance free.

2. In corrosive or abrasive environments, clean, lubricate, or change more frequently.

3. When fuel with poor quality is used, check, drain, and change more frequently.

manual de mantenimiento de motor mitsubishi s4s de mini cargador cat

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